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Mazda RX7 RX-7 1993 All Service Repair Manual

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The Mazda RX-7, specifically the FD generation, represents a pinnacle of rotary engine sports car design, produced from 1993. Known for its distinctive twin-rotor, twin-turbocharged 13B-REW engine, this performance coupe...
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Art.-Nr: 105286
Stichworte: 1993 Car Cars Mazda Misc RX-7 RX7
Mazda RX7 RX-7 1993 All Service Repair Manual
The Mazda RX-7, specifically the FD generation, represents a pinnacle of rotary engine sports car design, produced from 1993. Known for its distinctive twin-rotor, twin-turbocharged 13B-REW engine, this performance coupe offers exceptional handling and a unique driving experience, underscored by its balanced chassis and advanced aerodynamic development. With its compact packaging, low center of gravity, and commitment to a pure sports car ethos, the RX-7 has earned accolades such as Car and Driver's 10Best and Motor Trend's Import Car of the Year. Its engineering quality and reliability, particularly concerning its innovative rotary powertrain, make it a sought-after vehicle for enthusiasts and collectors alike. This Factory Service Manual (FSM) is an indispensable resource for all aspects of Mazda RX-7 (FD3S) maintenance and repair. Covering over 1000 pages, it provides comprehensive, in-depth information for owners, mechanics, and technicians. The manual details everything from routine scheduled maintenance, such as oil changes and fluid flushes, to complex engine rebuilds of the rotary powertrain and overhaul of the drivetrain, suspension, steering, and braking systems. It also includes vital technical specifications, diagnostic procedures, troubleshooting charts, and detailed wiring diagrams for the electrical system, ensuring that the vehicle's unique rotary technology and performance-oriented systems can be maintained effectively and efficiently.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
RX-7
Model Generation:
FD
Model Year:
1993
Codes
Chassis Code:
FD3S
👋 Introduction
Market Position
Market Segment:
Sports Car, Performance Coupe
Target Audience:
Enthusiasts, DIY mechanics, professional technicians
Competitive Analysis
Key Competitors Era:
Nissan 300ZX (Z32), Toyota Supra (JZA80), Mitsubishi 3000GT/GTO
Key Features
Unique Selling Proposition:
Rotary engine technology, balanced chassis, exceptional handling
Manual Value Proposition:
Essential resource for maintaining and repairing the complex rotary powertrain and performance-oriented systems
📋 Manual Details
Coverage Areas
Primary Coverage:
All Service and Repair
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Overhaul
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Rotary engine (13B-REW) rebuild, lubrication system, cooling system, fuel injection system, ignition system, starting and charging system, emission control system
Drivetrain:
Clutch system, transmission (R154 derivative), propeller shaft, driveshaft, differential, axle shafts
Suspension And Steering:
Front and rear suspension components, steering gear, power steering system, wheel alignment specifications
Brakes:
Front and rear brake systems (discs), ABS system, parking brake
Electrical System:
Wiring diagrams, lighting, instruments, switches, power distribution, fuse and relay locations, body control modules
HVAC And Comfort:
Air conditioning system, heater, ventilation
Body And Chassis:
Exterior body panels, interior trim, safety structures, body repairs, corrosion prevention
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug changes (apex seals, etc.)
Diagnostic Procedures:
Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs), OBD-II scan tool procedures
Repair Procedures:
Step-by-step repair instructions for all major vehicle systems, including engine teardown and reassembly, transmission overhaul, brake caliper replacement, etc.
Technical Specifications:
Torque specifications, clearances, tolerances, fluid capacities, electrical values
Technical Depth
Depth Of Coverage:
Comprehensive, from basic maintenance to full engine rebuilds and electrical system diagnostics
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing individual sections or the entire manual
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
13B-REW
Engine Type:
Twin-Rotary, Twin-Turbocharged
Displacement Cc:
1308 cc
Rotor Housing Design:
Oversquare design with specific internal clearances for optimal sealing
Apex Seals Material:
High-temperature resistant alloy (specific composition detailed in manual)
Performance
Horsepower Hp:
255 hp @ 6500 rpm (JDM spec), 255 hp @ 6500 rpm (USDM spec)
Torque Lb Ft:
217 lb-ft @ 5000 rpm (JDM spec), 217 lb-ft @ 5000 rpm (USDM spec)
Redline Rpm:
8000 rpm
Fuel System
Fuel Injection Type:
Sequential Electronic Fuel Injection (SEFI)
Turbochargers:
Sequential twin-turbo system (primary and secondary)
Fuel Type Recommended:
91+ Octane Unleaded Gasoline
Ignition System:
Electronic ignition with trailing and leading spark plugs per rotor
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (less common, primarily for specific markets)
Features
Clutch Type:
Hydraulically actuated, single-plate dry clutch
Transmission Fluid Type:
GL-4 or GL-5 Gear Oil (specific viscosity like 75W-90 recommended, check manual for precise fill)
📐 Dimensions
Exterior
Length Mm:
4280 mm
Width Mm:
1750 mm
Height Mm:
1230 mm
Wheelbase Mm:
2505 mm
Weights
Curb Weight Kg:
1320-1370 kg (depending on trim and options)
Gross Vehicle Weight Rating Kg:
1700 kg (approximate)
🛡️ Safety Features
Ratings
NHTSA Ratings Era:
Likely not rated under modern stringent NHTSA standards, focus on structural integrity of the era
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most trims
Traction Control:
Optional, depending on market and trim level
Passive Features
Airbags:
Driver and passenger airbags
Seatbelts:
Three-point inertia reel seatbelts
Chassis Design:
Advanced chassis with emphasis on rigidity and weight distribution for safety and handling
💡 Technology Features
Infotainment
Audio System:
Factory premium audio system (e.g., Bose on some trims), cassette deck, optional CD player
Climate Control:
Manual or automatic climate control
Driver Assistance
Cruise Control:
Standard on most models
Connectivity
Connectivity Era:
Limited by modern standards; focus on vehicle-integrated systems
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first (severe service recommendations apply)
Spark Plug Replacement:
Refer to manual for specific intervals; crucial for rotary engine health
Coolant Flush:
Every 2 years or 30,000 miles (50,000 km)
Timing Belt Alternative:
Rotary engines do not have timing belts; they use chain-driven components or direct drive for camshafts
Fluid Specifications
Engine Oil Spec:
API SG or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific viscosity based on climate)
Coolant Type:
Mazda Long Life Coolant (Blue) or equivalent ethylene glycol-based coolant
Brake Fluid Spec:
DOT 3 or DOT 4
Power Steering Fluid:
Mazda Genuine ATF or Dexron III/Mercon equivalent
Known Issues
Rotary Engine Common Issues:
Apex seal wear, oil seal failure, coolant seal failure (overheating), vacuum hose leaks, turbocharger issues, carbon buildup
Fd Specific Issues:
Sequential twin-turbo system failure, intercooler splitting, fuel pump failure, ignition system components
Maintenance Tips
Prevention Strategies:
Regular oil changes with quality oil, proper engine warm-up and cool-down, careful monitoring of coolant levels, clean air filters, avoid prolonged idling
📚 Vehicle History
Brand Heritage
Mazda Rotary History:
Mazda's long-standing commitment to rotary engine technology, dating back to the Cosmo and RX series
Model Evolution
Rx7 Generations:
SA/FB (1st Gen), FC (2nd Gen), FD (3rd Gen)
Fd Development:
Designed by Yoichi Satoh, focused on a pure sports car experience, extensive aerodynamic development
Fd Design Philosophy:
100:0 weight distribution, compact engine packaging for low center of gravity
Production
Production Years Fd:
1992-2002
Manufacturing Plant:
Hiroshima, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Award:
Car and Driver's 10Best list in 1993
Motor Trend Award:
Motor Trend's Import Car of the Year for 1993
Ratings
Performance Review Consensus:
Universally praised for its handling, balance, and unique rotary engine performance
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